Decorative colored particle dispersion for use in surface coating compositions and method for making same

ABSTRACT

The present disclosure generally relates to various composite slurries for use in seamless surface coverings and various methods for making the same. In particular, the present disclosure teaches various composite slurry compositions comprising, for example, a clear hardening material, a plurality of particles, a stabilizing filler, and an aggregate. Additionally, the present disclosure teaches various methods of forming composite slurry compositions for use in seamless surface coverings.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of and claims priority toU.S. Patent Application Ser. No. 13/015,189, filed Jan. 27, 2011, andentitled, “DECORATIVE COLORED PARTICLE DISPERSION FOR USE IN SURFACECOATING COMPOSITIONS AND METHOD FOR MAKING SAME.” The '189 applicationis a nonprovisional application of and claims priority to U.S. PatentApplication No. 61/300,407, filed Feb. 1, 2010, and entitled,“DECORATIVE COLORED PARTICLE DISPERSION FOR USE IN SURFACE COATINGCOMPOSITIONS AND METHOD FOR MAKING SAME.” The contents of the abovereferenced applications are incorporated by reference herein in theirentirety.

FIELD

The present disclosure generally relates to various composite slurriesfor use in seamless surface coverings and methods for making the same.In particular, the present disclosure teaches various composite slurrycompositions comprising, for example, a clear hardening material, atleast one particle, a stabilizing filler, and an aggregate.Additionally, the present disclosure teaches various methods of formingcomposite slurry compositions for use in seamless surface coveringscomprising, for example, creating an admixture of dry ingredientscomprising at least one particle, a stabilizing filler, and anaggregate, and mixing said admixture with a clear hardening material.

BACKGROUND

Chemical surface covering materials may be used for flooring and providea clean, seamless solution for flooring found in residential, commercialand industrial areas. Currently, both commercially and residentially,there are many different types of chemical surface covering materialsthat yield a seamless surface on a substrate. Chemical surface coveringmaterials may be used on a variety of substrates, such as concrete,wood, and the like. These chemical surface covering materials typicallyconsist of a clear hardening material and a group of particles. Mostcommonly, the clear hardening material, such as polyester, urethane, orepoxy compounds, is applied in viscous form to a substrate. Then, agroup of particles is broadcast or distributed on top of the clearhardening material, and the coating is allowed to cure. Once cured, theresultant surface covering is nearly or completely seamless.

As will be discussed below, such surface coating systems are typicallyapplied by a trowel, a roller, or a squeegee. Unfortunately, currentchemical surface covering materials require that the particles bedispersed after the hardening material has been applied to thesubstrate. This is typically done by hand and results in non-uniformdistribution of particles across the x, y and z axes of the coatedsurface due to diffusion limitations. Thus, there is a need for acomposite slurry composition for use in seamless surface coverings thatprovides for uniform particle distribution and allows for a moreefficient installation process.

SUMMARY

The present disclosure generally relates to various composite slurriesfor use in seamless surface coverings and various methods for making thesame. In particular, a composition is provided comprising a clearhardening material, a plurality of particles, a stabilizing filler, andan aggregate configured to cooperate with said stabilizing filler toprovide uniform suspension of said plurality of particles.

Further, a method is provided comprising creating an admixture of dryingredients comprising a plurality of particles, a stabilizing filler,and an aggregate, mixing said admixture with a polymeric material toform a precursor composite slurry having a uniform suspension of saidparticle.

In various embodiments, the composite slurry for use in seamless surfacecoverings comprises a clear (non-pigmented) hardening material having anactivated viscosity of about 300 CP to about 800 CP, a plurality ofparticles, a stabilizing filler, and an aggregate.

In various embodiments, the method of forming a composite slurrycomposition for use in seamless surface coverings comprises mixingtogether a clear (non-pigmented) polymeric liquid, a plurality ofparticles, a stabilizing filler, and an aggregate that cooperate toprovide a slurry of homogenously suspended solids that flow uniformly ina cohesive manner when applied to a surface.

Accordingly, in various embodiments, the slurry is uniformly distributedover a desired surface area of application with simple tools (such as anotched trowel, a notched squeegee, or a gauge rake) to produce aself-leveling, uniform coating, whereby the particles substantiallycover the substrate to conceal the underlying surface and may provide auniform decorative effect having a granulate appearance and a smoothsurface profile.

These and other advantages of the composite materials and methods formaking the same according to various aspects and embodiments of thepresent invention will be apparent to those skilled in the art uponreading and understanding the following detailed description.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure provides a composition wherein one or more of thecomposition's constituent components cooperate to resist sedimentaryforces that cause an irregular deposition of material when distributedover a surface, even large surfaces. Thus, in various embodiments, thecompositions described herein provide composite slurry that is easy toapply and produces a smooth surface finish when cured.

In various embodiments, the disclosed composite slurry has a high ratioof solids to liquids, yet flows readily when distributed to produce auniform, self-leveling coating. The resulting coating thickness tends tobe sufficient to cover imperfections (divots, cracks, protrusions) inthe underlying substrate. An exemplary coating thickness may range fromabout 40 mils to about 90 mils, Furthermore, the liquid film curesin-situ to produce a coating having enhanced durability, compressionstrength, ability to dissipate heat, and decreased permeability.

Without limiting the scope of the present disclosure, the variousembodiments of composite slurries and methods described herein may beused to create architectural panels, tiles, wall coverings, and castingof ornamental objects. In addition, in various embodiments, thecomposite slurries and methods described herein may be used to create adecorative load bearing sandwich structure having an inner core (e.g.,foam) encompassed between an outer structure load bearing membrane. Oneexample of this application is demonstrated by the construction of asurfboard.

In various embodiments, the crystalline structure of the aggregate andthe stabilizing filler are sufficiently transparent when wetted by theclear hardening material such that the resulting composition remainssubstantially transmissive to visible light, thus allowing the particlesto visually project through the resulting composition to produce ahomogenous, uniformly distributed granulate appearance when viewed fromabove. For example, the aggregate and the stabilizing filler may have arefractive index ranging between 1.5 and 1.6 when wetted by the clearhardening material. The clear hardening material may be tinted totransmit certain colors, though still remaining substantiallytransmissive to visible light. In further embodiments, however, theclear hardening material may be opaque or translucent during applicationand may cure to be at least partially transmissive to visible light.

Additionally, in an various embodiments, the combination of solids(e.g., a plurality of particles, a stabilizing filler, and an aggregate)produce an admixture that is proportioned to facilitate combining withthe clear hardening material with simple volume ratios to minimizecomplexity of on-site (in-the-field) mixing and installation. In anvarious embodiments, desired results have been produced with mixtures(volume ratio of admixture to clear hardening material) ranging fromabout 0.5:1.0 to about 1.5:1.0, from about 0.75:1.0 to about 1.25:1.0,and about 1:1 (volume:volume).

Stabilizing Filler

Solid materials may negatively affect a chemical surface coveringmaterial's ability to transmit visible light and/or selectively transmitonly particular colors. For example, conventionally used solid materialsmay add a white or gray hue (“cloudy” or “milky” contamination) to aresulting composite slurry and degrade the decorative impact of theparticles included in the mixture. Thus, various embodiments, thestabilizing filler may comprise any stabilizing filler that does notnegatively affect visible light transmission clarity or otherwisedegrade the impact of the particles included in the mixture.

In various embodiments, the stabilizing filler may comprise micro-glassmilled fiber. In particular, in further embodiments, the fiber is aman-made material composition comprising of silica oxide, calcium,aluminum, magnesium, and boron fused in an amorphous vitreous state.

In various embodiments, the preferred average fiber diameter is about 10microns to about 20 microns. More preferably, in various embodiments,the average fiber diameter may be about 16 microns. Additionally, invarious embodiments, the average fiber length is from about 100 micronsto about 300 microns. The average fiber length is about 220 microns invarious embodiments.

In various embodiments, the average fiber aspect ratio is about 10:1 toabout 20:1, though in further embodiments the average fiber aspect ratiois about 14:1.

Smaller fibers may also be used by adjusting the relative ratio ofparticles and aggregate to produce the desired flow, self-levelingcharacteristics, and post-cure surface profile. One example of analternative stabilizing filler is micro-glass milled fiber having anaverage fiber diameter of 16 microns and an average fiber length of 150microns, yielding an average aspect ratio of 11:1.

In various embodiments, the stabilizing filler is micro-glass milledfiber as disclosed above comprising silica oxide, calcium, aluminum,magnesium and boron, combined with vitreous calcium aluminosilicate.Vitreous calcium aluminosilicate is typically manufactured by heating ablend of ground silica, lime, and alumina compounds to a molten statewhich is then solidified by quench cooling and ground to a fine powderwith a specific gravity of 2.6, a hardness of 5.5 Mohs, and a refractiveindex of 1.56.

Additionally, in various embodiments, vitreous calcium aluminosilicatemay be added as a stabilizing filler in a powder form that is finer thanother stabilizing components so as to reduce surface imperfections ofthe resulting coating. A reduction of surface imperfections results asvitreous calcium aluminosilicate particles disperse in both solid anddissolved forms within a clear polymeric material (e.g., a syntheticresin) during the mixing, placement, and curing process. Furthermore,vitreous calcium aluminosilicate is a certified 100% post industrialrecycled product that will contribute points to the U.S. Green BuildingCouncil's Leadership in Energy and Environmental Design (LEED)certification for building sustainable structures.

In various embodiments, a stabilizing particle may be added as astabilizing filler to enhance fluid flow due to added cohesiveness ofparticles in the resulting mixture, which provides improved compressionstrength, decreased permeability, and increased durability. In variousembodiments, the stabilizing particle may comprise a particle rangingbetween about 10 and about 20 microns (with 95% passing through no. 325mesh) in size. Additionally, in various embodiments, the stabilizingparticle may comprise any structure or chemical species capable of orconfigured to transmit ultraviolet light. This is particularly usefulfor use with clear hardening materials that can be cured by exposure toultraviolet light.

In various embodiments, materials that may be used as stabilizing fillerinclude substances with particle morphologies of fibers or plateletshaving an average particle size ranging between about 5 microns andabout 30 microns. These substances include, but are not limited to,Wollastonite, 1250 Novacite®, Daper Novacite®, silica flour, mica,alumina, and calcium carbonate. In general, hardness of thesealternative stabilizing fillers range between 3 Mohs and 8 Mohs, andspecific gravities range between 2.5 and 2.9. As a result, use of thesestabilizing fillers requires a corresponding adjustment of respectivemixing ratios to produce acceptable flow and self-levelingcharacteristics.

Aggregrate

As mentioned above, various embodiments include an aggregate thatcooperates with the particles and/or stabilizing filler to provide acomposite slurry with predictable clarity, flow, and self-levelingcharacteristics.

In various embodiments, the aggregate may comprise a sub-roundmicrocrystalline silica produced from industrial quartz having aspecific gravity of about 2.65 and a hardness of about 7 Mohs. Invarious embodiments, an aggregate comprises microcrystalline silicahaving a high chemical purity that principally comprises silicon dioxide(SiO₂) and has a uniform particle size distribution. Moreover, invarious embodiments, the aggregate has a refractive index such that itdoes not negatively affect the visual properties of the compositeslurry, such as the composite slurry's ability to transmit visiblelight. For example, an aggregate may have a refractive index rangingfrom about 1.5 to about 1.6.

In various embodiments, an aggregate comprising microcrystalline silicais used having a composition profile as follows:

TYPICAL COMPOSITION PROFILE Mean Percentage by Weight Silicon Dioxide(SiO₂) 99.726 Iron Oxide (Fe₂O₃) 0.021 Aluminum Oxide (Al₂O₃) 0.067Calcium Oxide (CaO) 0.042 Titanium Dioxide (TiO₂) 0.013 Magnesium Oxide(MgO) 0.011 Potassium Oxide (K₂O) 0.017 Sodium Oxide (Na₂O) 0.003 Losson Ignition (L.O.I.) 0.101

In various embodiments, an aggregate comprising microcrystalline silicais used having a particle size distribution as follows:

PARTICLE SIZE ANALYSIS Typical Mean % Retained on Individual Sieves Mesh(ASTM E-11) % 50 0.1 70 1.1 100 40.8 140 47.1 200 109 270 TR

Additionally, in various embodiments, the aggregate may comprise anystructure or chemical species capable of or configured to transmitultraviolet light or conducting electricity. This is particularly usefulfor use with clear hardening materials that can be cured by exposure toultraviolet light.

Particles

In addition to the stabilizing filler and the aggregate, in variousembodiments, a plurality of particles is added to the admixture. Asdiscussed above, these particles may be added to the composite slurryfor either functional and/or decorative utility.

In various embodiments, colored particles are added into the admixtureand resulting composite slurry. In such embodiments, the chemicalcomposition of the colored particles may include a polymer, a filler,and a pigment. Also in such embodiments, the polymer may comprise one ormore of the following: an acrylic, polyvinyl acetate (PVA), polyvinylchloride (PVC), polyester, polymethylmethacrylate, cellulosic resins, ormethylmethacrylate (MMA). In addition, in various embodiments, specialtypigments may be used to produce colored particles that are fluorescent(black light activated), phosphorescent (glow-in-the-dark), andtranslucent (semi-transparent).

In various embodiments, the particles (colored or uncolored) maycomprise one or more of any metal filing, mica, glitter, rubber,synthetic rubber such as ethylene propylene diene monomer (EPDM),colored quartz, crushed marble, or glass. In various embodiments, theparticles (colored or uncolored) may comprise one or more of any organicmaterial including, but not limited to, sea shells (like oysters orclams), cork, or walnut shells.

Additionally, in various embodiments, the particles may comprise anystructure or chemical species capable of or configured to transmitultraviolet light or conducting electricity. This is particularly usefulfor use with clear hardening materials that can be cured by exposure toultraviolet light.

In various embodiments, the colored particles are color chips (alsoknown as flakes or fleck) having a thickness ranging between about 1 milto about 15 mils with irregular platform shapes generally encompassedwithin a circular area having a diameter ranging between about 1/64 inchto about ¼ inch. In further embodiments, the colored particles are colorchips (also known as flakes or fleck) having a thickness ranging betweenabout 3 mil to about 10 mils. In still further embodiments, the coloredparticles are color chips (also known as flakes or fleck) having athickness ranging between about 4 mils to about 6 mils.

Colored particles that are relatively thin (3 mils to 6 mils) aredesired to produce coatings with a smooth surface. In accordance withvarious embodiments, thicker particles can be used if a rough surfacefinish is desired.

In various embodiments, the colored particles are suitable for use withany clear hardening material. Particularly, the colored particles may besuitable for use with, for example, one or more of epoxy, polyester,polyurethane, urethane, acrylic, polyurea, polyaspartic,polymethylmethacrylate, and methylmethacrylate (MMA).

In various embodiments, pigment may be added into the admixture and/orthe resulting composite slurry, to color the overall composite slurry.In such embodiment, pigment may also include pigment(s) selected from avariety of materials. Pigment may be added in an amount effective toalter the coating or flooring material color from the unpigmented color,i.e. to achieve a desired color.

Clear Hardening Material

In various embodiments, once the admixture is created, it is then mixedwith a clear hardening material. The clear hardening material may cureslowly and the solids may remain homogeneously suspended to allowsufficient working time (for example, approximately about 20 to about 30minutes) required to distribute (e.g., trowel) the composite slurryevenly while facilitating multiple batch applications of the compositeslurry. In this manner, large surface areas are coated without leavingseams, discontinuities, or surface irregularity (e.g., undulations) assubsequent batch applications of the slurry adjoin, abut, and otherwiseinteract with previously applied applications.

The clear hardening material comprises any polymeric material capable ofpolymeric cross linking to form a hardened or cured matrix. In variousembodiments, the clear hardening material comprises a polymeric material(also referred to as a synthetic resin), wherein the polymeric materialcomprises at least one of an ester compound, a urethane compound, anacrylic compound, a urea compound, an aspartic compound, amethylmethacrylate (MMA) compound, and/or an epoxy compound. However,any polymeric material known or unknown in the art that would providefor a clear medium to integrate the admixture described herein and thatwill cure to form a seamless, durable coating is contemplated herein.

In various embodiments, the clear hardening material comprises amultiple component system such that when mixed with a hardenercomponent, the clear hardening material cures as the result of anexothermic reaction or cures where stimulated with ultraviolet light.

In various embodiments, the hardener may include any chemical speciescapable of initiating polymer cross linking, or a polymeric reaction.Examples of some potential hardeners include methyl diisocyanate,triethyl diisocyanate, methyl ethyl ketone peroxide, diethylenetriamine, triethylene tetramine, tetra ethylene pentamine and/orcycloaliphatic amines.

In various embodiments, the clear hardening material may comprise awater based epoxy. Water based epoxies may appear opaque or translucentduring application, but cure to be at least partially transmissive tovisible light. In such embodiments, cured water based epoxies createporous coatings that may reduce or eliminate the need for theapplication of a primer or other vapor barrier to a substrate.

Methods of Application

There are two primary types of seamless surface coating materials andapplications. The first is a mortar type system wherein rock orparticles may be mixed with a castable liquid and cured on a surface,or, in the alternative, wherein a castable liquid may be troweled on asurface and a rock or particle may be broadcast across the surface andcured.

The second type of seamless surface coating materials is a particle orchip broadcast system. In both of types of seamless surface coatingmaterials, a surface is prepped either mechanically (i.e. sanding,grinding, shot blasting, planing, etc.) or chemically (i.e. with an acidetch, etc). The prepped surface may then be coated with a suitableprimer or other vapor barrier. In the mortar-type system, a castablematerial with rock or particles mixed is then applied to a surface,though is typically of such high solids content that the material is notself leveling. This results in a surface with exposed particles or rockand a rough uneven surface. Thus, this mortar-type system requiresiterative grinding and top coats to provide a uniform and desirablesurface profile, which tends to be labor intensive.

In the particle or chip broadcast system, after substrate/surfacepreparation, a liquid polymer is applied to the substrate. Particles(chips or rock) are broadcast into the liquid and the combination isallowed to cure. Thereafter, the surface is scraped to remove excessparticles and a top coat is applied to provide a desired surfaceprofile. Again, this process is labor intensive.

Thus, there is a need in this field for a composite slurry compositionfor use in seamless surface coverings that provides for a level surfacewithout substantial preparatory work to the underlying substrate andeliminates multiple application steps to provide a desired surfaceprofile.

In various embodiments, the admixture comprising a plurality ofparticles, a stabilizing filler, and an aggregate may be mixed with apolymeric material to form a precursor composite slurry with a uniformsuspension of particles. Stated another way, in accordance variousembodiments, the admixture comprising a plurality of particles, astabilizing filler, and an aggregate may be mixed with the polymericmaterial of a two component synthetic resin system. This allows for theshipping and handling of the precursor composite slurry prior to addingthe chemical hardener, as discussed herein, to from the final compositeslurry. Thus, in accordance with various embodiments, the precursorycomposite slurry would not harden or cure until the installer was readyto apply the composite to a surface.

Additionally, one may produce and sell an admixture comprising aplurality of particles, a stabilizing filler, and an aggregate that isintended to be mixed with a single or multiple component polymericsystem that hardens or cures to provide a seamless surface covering.Similarly, one may produce and sell an admixture comprising a pluralityof particles, a stabilizing filler, and an aggregate that has been mixedwith any polymeric material, such as a single component polymer system,wherein the admixture/polymer material precursor composite slurry will,in turn, be activated prior to application.

In various embodiments, the various composite slurries disclosed hereinallow for application of a material that already contains particles,decorative or functional, in any manner wherein the applied force of theapplication tool is substantial parallel to the finished surface of thecured composite. For example, the application tool, in variousembodiments, may be a rake. More specifically, the rake may comprise anelongated handle and a troweling surface configured to be used bypulling the rake across composite slurry applied to a surface. Forexample, this rake may be a steel rake about 18 to about 24 inchesacross or any tool configured to provide an even coat of the compositeslurry on a surface, wherein said coat of composite slurry may be about30 mils to about 80 mils thick.

In various embodiments, as discussed above, the coat of composite slurrymay be about 40 to about 90 mils thick. Following the initialapplication and the distribution of composite slurry on a surface, aloop roller may be used to move material (as particles remain suspended)to finely adjust, level, and distribute the composite surface coating.

The following examples are intended to provide exemplary embodiments ofvarious composite slurry compositions and in no way limit the scope andbreadth of the present disclosure.

EXAMPLE 1

Example 1 illustrates an admixture comprising fiber as the onlystabilizing filler.

Admixture (% by Weight)

Colored Particles 35% “E” size color chip blend produced by ChipsUnlimited, Inc. (B99-220E) Micro-Glass Milled Fiber 20% Average fiberdiameter = 16 microns. Average fiber length = 220 micronsMicrocrystalline Silica 45% An exemplary chemical analysis and particlesize analysis is provided above.

Admixture & Synthetic Resin Combination

Clear Synthetic Liquid Resin Epoxy (2 parts A: 1 part B). Activatedviscosity = approx. 400 CP Combined Resin (Epoxy)/Admixture (v:v)1.125/1.00

EXAMPLE 2

Example 2 illustrates an admixture comprising vitreous calciumaluminosilicate and fiber as the stabilizing filler.

Admixture (% by Weight)

Colored Particles 33% “E” size color chip blend produced by ChipsUnlimited, Inc. (B99-220E) Micro-Glass Milled Fiber 11% Average fiberdiameter = 16 microns. Average fiber length = 220 microns. VitreousCalcium Aluminosilicate 13% Average particles size = approx. 12 microns.95% passing through 325 mesh. Microcrystalline Silica 43% An exemplarychemical analysis and particle size analysis is provided above.

Admixture & Synthetic Resin Combination

Clear Synthetic Liquid Resin Epoxy (2 parts A: 1 part B). Activatedviscosity = approx. 400 CP Combined Synthetic Resin (Epoxy)/Admixture(v:v) 1.00/1.00

EXAMPLE 3

Example 3 illustrates an admixture comprising a glitter particle.

Admixture (% by Weight)

Colored Particles 33% 99% (by weight) “E” size color chip blend producedby Chips Unlimited, Inc. (B99-220E) combined with 1% (by weight) MV1silver (regular) glitter. Micro-Glass Milled Fiber 11% Average fiberdiameter = 16 microns. Average fiber length = 220 microns. VitreousCalcium Aluminosilicate 13% Average particles size = approx. 12 microns.95% passing through 325 mesh. Microcrystalline Silica 43% An exemplarychemical analysis and particle size analysis is provided above.

Admixture & Synthetic Resin Combination

Clear Synthetic Liquid Resin Epoxy (2 parts A: 1 part B). Activatedviscosity = approx. 400 CP Combined Synthetic Resin (Epoxy)/Admixture(v:v) 1.00/1.00

EXAMPLE 4

Example 4 illustrates an admixture comprising multiple particles withdifferent dimensions to provide a multi-grain aesthetic.

Admixture (% by Weight)

Colored Particles 33% Color chips produced by Chips Unlimited, Inc. −50% (by weight) C600E (white) “E” size + 46% C610E (black) “E” size + 4%C61014 (black) ¼ inch. Micro-Glass Milled Fiber 11% Average fiberdiameter = 16 microns. Average fiber length = 220 microns. VitreousCalcium Aluminosilicate 13% Average particles size = approx. 12 microns.95% passing through 325 mesh. Microcrystalline Silica 43% An exemplarychemical analysis and particle size analysis is provided above.

Admixture & Synthetic Resin Combination

Clear Synthetic Liquid Resin Epoxy (2 parts A: 1 part B). Activatedviscosity = approx. 400 CP Combined Synthetic Resin (Epoxy)/Admixture(v:v) 1.00/1.00

EXAMPLE 5

Example 5 illustrates an admixture comprising glow-in-the-darkparticles.

Admixture (% by Weight)

Colored Particles 33% Color chips produced by Chips Unlimited, Inc. −50% (by weight) C600E (white) “E” size + 46% C610E (black) “E” size + 4%C27-80214 (Green Glow) ¼inch. Micro-Glass Milled Fiber 11% Average fiberdiameter = 16 microns. Average fiber length = 220 microns. VitreousCalcium Aluminosilicate 13% Average particles size = approx. 12 microns.95% passing through 325 mesh. Microcrystalline Silica 43% An exemplarychemical analysis and particle size analysis is provided above.

Admixture & Synthetic Resin Combination

Clear Synthetic Liquid Resin Epoxy (2 parts A: 1 part B). Activatedviscosity = approx. 400 CP Combined Synthetic Resin (Epoxy)/Admixture(v:v) 1.00/1.00

EXAMPLE 6

Example 6 illustrates an admixture comprising glitter particles only.

Admixture (% by Weight)

Colored Particles  4% MV1 (regular) glitter from Chips Unlimited, Inc.Micro-Glass Milled Fiber 16% Average fiber diameter = 16 microns.Average fiber length = 220 microns. Vitreous Calcium Aluminosilicate 19%Average particles size = approx. 12 microns. 95% passing through 325mesh. Microcrystalline Silica 61% An exemplary chemical analysis andparticle size analysis is provided above.

Admixture & Synthetic Resin Combination

Clear Synthetic Liquid Resin Epoxy (2 parts A: 1 part B). Activatedviscosity = approx. 400 CP Combined Synthetic Resin (Epoxy)/Admixture(v:v) 1.00/1.00

The present inventions have been described above with reference to anumber of exemplary embodiments. It should be appreciated that theparticular embodiments shown and described herein are illustrative ofthe invention and its best mode and are not intended to limit in any waythe scope of the inventions. Those skilled in the art having read thisdisclosure will recognize that changes and modifications may be made tothe exemplary embodiments without departing from the scope of thepresent inventions. For example, while the compositions, systems, andmethods of manufacture contemplated in the present inventions areillustrated with examples of preferred embodiments directed to seamlessfloor coating applications, without limitation, the present inventionsare suitable for use as any surface coating. Although certain aspects ofthe inventions are described herein in terms of exemplary embodiments,such aspects of the inventions may be achieved through any number ofsuitable means now known or hereafter devised. Accordingly, these andother changes or modifications are intended to be included within thescope of the present inventions.

1. A method comprising: creating an admixture of dry ingredientscomprising a plurality of particles, a stabilizing filler, and anaggregate, wherein the aggregate is between 43% and 61% by weight of theplurality of particles, the aggregate and the stabilizing filler,wherein the plurality of particles is between 4% and 35% by weight ofthe plurality of particles, the aggregate and the stabilizing filler,and wherein the stabilizing filler is between 20% and 35% by weight ofthe plurality of particles, the aggregate and the stabilizing filler;mixing the admixture with a polymeric material to form a compositeslurry having a uniform suspension of said particle.
 2. The method ofclaim 1, further comprising combining the composite slurry with achemical hardener to form an activated composite slurry.
 3. The methodof claim 2, further comprising applying the composite slurry to asurface to produce a substantially seamless surface covering.
 4. Themethod of claim 3, wherein a volume ratio of the admixture to thepolymeric material and the chemical hardener ranges from about 0.5:1.0to about 1.5:1.0
 5. The method of claim 3, wherein the applying theactivated composite slurry on the surface comprises using a rake with anelongated handle and a troweling surface.
 6. The method of claim 4,wherein the composite slurry is applied to a thickness of about 40 milsto about 90 mils.